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Supplier Audit Form - Excel

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									                                                Igloo Supplier Audit Form
                                                     Form No. IPSQA-FORM-SUPPLIER AUDIT - 0022
                                                                              Audit Date:
                                                                            Audit Team:



Supplier Information:
Company Name
Div./Subsidiary of



Address



Telephone
Fax
                                                                                                    Name            Phone               E-mail
President/General Manager
Customer Service Manager
Quality Assurance Manager
Sales Manager
Chief Financial Officer
Production Manager
Technical/Engineering Manager
Materials/Purchasing Manager
Shipping Manager

Supplier Audit:

Ranking Criteria 1 to 5
1 = Does not exist
2 = Developmental
3 = Meets intent (minimal or no validation)
4 = Meets requirement (validated)
5 = Exceeds base requirements (competitive advantage)

                                                                                                                                  Section Average
                                                                                            Objective Evidence       Score
                                                                                                                                      Rating:
1 FACILITIES AUDIT:


EXPECTATIONS: Buildings are in good condition and there is evidence that maintenance is performed regularly. There is sufficient capacity, no
excessive WIP backlog, and a demonstrated orderly flow of materials. There is adequate fire protection. ( Please take pictures as objective evidence)

Is plant layout adequate for work performed?
Is the layout conducive to an orderly flow of materials?
Is maintenance of the premises adequate?
Is general housekeeping acceptable?
Is all production equipment adequately maintained?
Is maintenance by a systematic preventative maintenance system?
Is there an appropriate and adequate fire protection system in place?
Does the current manufacturing capacity allow for flexibility and future growth?

Section Subtotal:                                                                                                      0                   0




                                                         60d5c369-5150-4b77-bf64-1fb1b5b965d2.xls                                          Page 1
2 QUALITY SYSTEMS:
EXPECTATIONS: All suppliers will have a documented Quality Policy that is communicated, understood and practiced by all employees.
Documented procedures will be in place that support the organization in a defect prevention mode. Regularly scheduled audits will be performed,
corrective action completed if required, and verified. There will be evidence of employee training in the quality process and for job proficiency.
2.1: Management Responsibilities
a) Who is responsible for ensuring that the quality policy is understood throughout all
levels of the organization? Include names and position descriptions.
b) How does your organization ensure that the quality policy is understood throughout all
levels of the organization? Provide evidence that demonstrates this.
c) Describe the positions and number of internal personnel responsible for performing
quality program reviews/audits. In doing so, please address the following:
   1) How often are these reviews/audits performed?
   2) Provide records of your last two internal reviews/audits

2.2: Design Control
1. Is there a standard procedure to control and verify the design of product?
2. Are the responsibilities and authorities of all personnel assigned to design and
development activities clearly defined and documented? What are their names and
Phone Numbers?
3. Are design reviews performed and documented by qualified personnel?
4. Are engineering resources available to support customer product development?
5. Is there a standard procedure to ensure that all design changes are identified,
documented, reviewed and approved?
6. Are product or component or tooling design adequately documented?
7. Are characteristics critical to safety and function identified and controlled in the
process by 100% gage control or SPC?
8. Are cosmetic conditions and allowances quantified?
9. Is there a procedure and personnel designated to track and report on new products
and/or tooling, test equipment, software, and production?
10. Is there a procedure for reviewing customer drawings, processes, and change
orders?
11. Is there a procedure to control the review, approval, retrieval, release and
distribution of controlled documentation including engineering drawings, and BOM?s,
manufacturing routings and instructions, and test and inspection instructions?
12. Is all controlled documentation used in manufacturing reviewed and approved by
designated authorities prior to release?
13. Are relevant documents available at all locations where the related operations are
performed?
14. Are records maintained which reflect an adequate history of specification changes?

2.3: Purchasing
a) Provide the documents that describe the type and extent of control exercised by your
company over subcontractors?
b) What requirements are used to evaluate and select subcontractors? Are
subcontractors required to meet any quality standards? Provide this documentation.
c) Do you have a "Vendor Rating System"? If so, please explain the system and show
where it is defined. In explaining, be sure to address the following:
   1) Do different evaluation/selection criteria apply for different types of subcontractors?
   2) What are the qualifications of the auditor evaluating the subcontractor?
   3) How can a subcontractor become disqualified?
d) Do you have an "Approved Supplier List"? If so, provide the list and state who is in
charge of maintaining and updating the list? Include names and position descriptions.

2.4: Product Identification and Traceability
a) Describe how product identification and traceability are maintained throughout
production, delivery, and installation and in explaining, be sure to address the following:
1) Are parts, lot, or batch numbers used? How are these number assigned?
2) Provide examples (e.g. pictures, labels) of where the product I.D. and traceability
information is marked on the finished product.
Note: Igloo requires all products approved to be identified by manufacturer name, part
number, and date of manufacture.

2.5: Process Control
a) How are production processes that affect quality identified and planned? Who is
responsible for identifying and planning these processes? Include names and position
descriptions.




                                                           60d5c369-5150-4b77-bf64-1fb1b5b965d2.xls                                          Page 2
b) What statistical techniques are used to monitor and verify process capability and
stability? Estimate the number of processes statistically monitored in your system.
Provide examples of control charting if used.
c) Has top management received statistical training? In answering this question, please
address the following:
1) What statistical training has top management received?
2) Does your company have SPC specialists available? If so, provide their contact
information.
3) Has anyone within your company received six-sigma training? If so, provide their
contact information.




2.6: Inspection and Testing
a) Describe your receiving inspection and testing procedures. In doing so, address the
following:
   1) What statistical sampling technique is used (e.g. 100% testing, random testing,
   etc.)?
   2) How are damaged goods handled?
   3) What data is maintained to provide feedback to your purchasing procedures?
b) Who is authorized to perform in process and final inspection testing?
Include names and position descriptions.
c) Provide the documentation that provides information regarding what products require
in-process inspections and testing and the procedures for conducting these inspections
and tests.
d) Describe the procedure when a product fails in-process or final inspection. In doing
so, please address the following:
1) How are inspection and testing results recorded?
2) Provide examples of these records showing whether the product passed or failed
inspections and identify the inspector.

2.6: Controlling Measuring and Test equipment
a) Describe the procedures used for inspection and calibration of tools, gauges, and test
equipment. In doing so, address the following:
1) Who ensures that measuring and test equipment is calibrated and adjusted at
predetermined intervals? Include names and position descriptions.
2) How are uncalibrated or outdated items identified and/or stored?
3) How are tools, gauges, and test equipment that require regular re-calibration
recalled?
b) What certifications of calibration are on file? Provide a copy of the last two
certificates.

2.7: Controlling Nonconforming Products
a) What formal organization procedures are established for the segregation of
discrepant material? Where are the procedures defined?
b) What formal company procedures are established for the identification and/or
marking of discrepant material? Provide examples (e.g. pictures, labels) of the
identification and/or marking of discrepant material.

2.8: Corrective and Preventative Action
a) Describe the procedures for implementing corrective action. In doing so, address the
following:
1) What triggers corrective action?
2) Who is responsible for investigating the causes of nonconformities and recording the
results of the investigation?
3) How do records indicate the nature of deficiencies and the positive corrective action
taken? Provide an example copy of these records.
b) Describe the procedures for implementing preventative action. In doing so, address
the following:
1) Who is responsible for determining and implementing the necessary steps to deal
with problems requiring preventive action? Include names and position descriptions.
2) How is the effectiveness of the preventative action measured?
c) Describe the procedure for handling customer complaints and reports of product
nonconformities.

Section Subtotal:                                                                                  0   0




                                                        60d5c369-5150-4b77-bf64-1fb1b5b965d2.xls       Page 3
3. CONTRACTS/CUSTOMER SERVICE AUDIT

EXPECTATIONS: Customer contracts will be reviewed to ensure compliance capability with all specifications prior to approval and acceptance. A
system is in place to ensure that internal operations focus on satisfying the external customer. The buyer at Igloo Products Corp. should be contacted
immediately if for any reason contractual requirements cannot be met.
1. Are procedures in place to ensure review and approval of contract requirements prior
to acceptance?
2. Are steps taken to ensure that contract requirements can be met?
3. Are plans established to met customer concerns and complaints?
4. Are concerns and complaints resolved promptly?
5. Are the following indicators monitored in order to determine problem areas and
trends, delivery, pricing, technical specifications, quality, and service?
6. Is the customer relationship periodically reviewed for improvement?

Section Subtotal:                                                                                                       0                  0


4. PRODUCTION PROCESS CONTROL AUDIT


EXPECTATIONS: The supplier has documented an effective manufacturing process and demonstrated initial or start-up process capability which
includes (1) sequence of operations, (2) process control points and methods, (3) evidence of process capability, and (4) an approved first piece
production sample.


1. Does the supplier inspect or otherwise verify purchased material/components prior to
use?
2. Are written inspection records maintained?
3. Are documented work instructions available which clearly define the manner of
production?
4. Are key process and product characteristics controlled at key points during production
by either gage or SPC?
5. Are standard workmanship criteria identified and documented or are limit samples
approved and controlled?
6. Is the status of all material, components and product adequately identified and
controlled at all times throughout the production process?
7. Is manufacturing performance data collected and analyzed to detect problem areas
and trends?
8. Are inspection, test and process control requirements adequate, controlled and
available to the personnel responsible for completion of the assigned work?
9. Is all production tooling and equipment reviewed, qualified and approved prior to use?
10. Are all process qualification and monitoring controls carried out in accordance with
sound, documented, statistical techniques?
11. Are adequate records of inspection and test maintained?
12. Is final verification performed per documented instructions prior to product release?
13. Is 100% final testing conducted on electrical, electro-mechanical and other critical
operating assemblies in such a manner as to maintain product integrity?
14. Is there a preventative maintenance program for production tooling?
15. Are first piece production samples 100% inspected and/or tested before submission
with qualification report?
16. Does the supplier utilize statistical methods for assuring that components are
produced within control limits (eg., histograms, X-Bar and R charts, capability studies,
etc.)?
17) Has top management received statistical training? In answering this question,
please address the following:
   a) What statistical training has top management received?
   b) Does your company have SPC specialists available? If so, provide their contact
   information.
   c) Has anyone within your company received six-sigma training? If so, provide their
   contact information.

Section Subtotal:                                                                                                       0                  0




                                                        60d5c369-5150-4b77-bf64-1fb1b5b965d2.xls                                            Page 4
5. MATERIAL HANDLING, STORAGE, PACKAGING & DELIVERY AUDIT


EXPECTATIONS: Defect prevention measures will be in place to ensure that materials and products are handled and stored without damage.
Packaging will be environmentally safe and adequate to protect product. There is evidence that a documented system is in place to define, review,
and disposition nonconforming materials, including records of appropriate corrective action. All shipping and documentation requirements will be met.

1. Are all materials and products handled in such a way as to prevent damage?
2. Are all materials and products clearly identified and stored in such a way as to
prevent damage and mix-ups?
3. Are special packaging requirements documented including product labeling?
4. Do packaging requirements include provision for identification of special materials
such as limited life, hazardous, etc.?
5. Are there prepackaging capabilities for customer product?
6. Are there appropriate equipment, systems, or procedures in place to ensure shipment
of exact required quantities?
7. Are all products protected during shipment and delivery in such a way as to prevent
damage?
8. Is supplier capable of supporting Igloo bar code and labeling requirements?
9. Is non-conforming or product-on-hold materials clearly designated and isolated
(physically and systematically) to insure materials is not used or shipped?

Section Subtotal:                                                                                                      0                   0



SCORE SUMMARY                                                                               Section Average
1 FACILITIES AUDIT:                                                                                           0
2 QUALITY SYSTEMS:                                                                                            0
3. CONTRACTS/CUSTOMER SERVICE AUDIT                                                                           0
4. PRODUCTION PROCESS CONTROL AUDIT                                                                           0
5. MATERIAL HANDLING, STORAGE, PACKAGING & DELIVERY AUDIT                                                     0


Audit Summary & Requested Actions:

SUMMARY REMARKS:




REQUESTED ACTIONS:




                                                       60d5c369-5150-4b77-bf64-1fb1b5b965d2.xls                                             Page 5

								
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